Final Report Summary - POWER-OM (Power consumption driven Reliability, Operation and Maintenance optimisation)
Executive Summary:
European manufacturers of machine tools are positioned in the manufacture of high value-added products. The fact that customers buy machines with high added value means that these machines are used in critical processes and therefore expect machines free of failures. In these machines, spindle faults are responsible for the most common and cost-intensive downtimes in machine-tools.
The normal strategy to keep these production systems in good conditions is to apply preventive maintenance practices and complement it with a supportive workforce “reactive” in the case of clearly detected malfunctions. This impact on quality, cost and in general, productivity. Added to this, the uncertainty of machine reliability at any given time, also impacts on product/production delivery times.
The use of intelligent predictive technologies could contribute to improve the situation, but these techniques are not widely used in the production environment. Sensors and other monitoring techniques required for the production environment are not so standard and require costly implementations.
Project has research in the development of those mechanisms that can make possible the implementation of a pro-active maintenance strategy:
• Machine tool health assessment using the Electric Signature Analysis technique. This has been applied to the most critical components (spindle and linear axis) that are responsible of more than 80% of the idle time.
• Machine working condition monitoring
• The collection and analysis of data at the fleet level
The technology developed is easy to implement and little intrusive, allowing the machine tool manufacturer:
• Be more pro-active regarding potential problems that the client may have,
• Conduct a faster and more accurate diagnosis,
• Provide recommendations for the future; for example, the spindle head which suits better the customer type of work.
This is something could be offered by the machine tool manufacturer as a standard feature. The efforts made by the manufacturer would be rewarded for its ability to anticipate problems and respond to customers more efficiently and orderly. Moreover, the machine manufacturer would have valuable information regarding the behaviour of the machine in relation to the use that would, among other things, future product enhancements.
The results can be categorized in two groups:
• Components that can be embedded in the machine as data loggers to save working conditions and to implement the finger print concept based on current signal capture and its analysis.
• e-Maintenance platform to aggregate the information coming from the fleet of machines. This includes the knowledge model to facilitate heterogeneous knowledge (i.e. data, information, results) retrieval and sharing on the basis of the monitored units composing the fleet. Final objective is to make periodic assessment of performance indices (health, energy consumption and other KPIs). The system generates also pro-active alarm when a drift in the machine tool performance or some component degradation is detected. The knowledge/data found in the fleet help also in the predictive diagnostic of the fault.
Project Context and Objectives:
PROJECT CONTEXT
Production systems deteriorate with the usage and age. The normal strategy to keep them in good conditions is to apply preventive maintenance practices, with a supportive workforce “reactive” in the case of clearly detected malfunctions or machine breakdowns. All these have an impact on quality, cost and in general, productivity. Added to this, the uncertainty of machine reliability at any given time, also impacts on product/production delivery times. It is known also that a worn-out or incorrectly assembled mechanism has higher energy consumption.
The use of intelligent predictive technologies and tools could contribute to improve the situation; it has been proven that deployment of these tools and techniques can detect malfunctions or potential breakdowns, and help and guide an anticipated solution. However the obvious of the advantages of a predictive strategy and techniques are not widely used in the production environment. There are many reasons for this, one of the main obstacles is providing a sound cost-benefit analysis for the business. Often sensors and monitors that are required for the production environment are non standard. Most applications that require a solution to particular problems are solved case-by-case basis with sensors have to be retro fitted to existing machines, which means the implementation is costly and requires machines down time for access and often ongoing monitoring making the cost benefits harder to quantify. Added to this, for some processes, retro fitting of addition monitoring sensors/devices is not possible due to machine configuration, process constraints and I.T. integrity concerns. Even machine integrated solutions are not installed widely at machine delivery phase. The monitoring requirement at machine order phase is often not a must requirement, but a might requirement, which leads to a cost reduction opportunity often used in the purchasing department.
Machine tool critical components:
From all the machines produced, machine tools are the most significant homogeneous group, in terms of value it could be up to 20%. The predictive strategies developed for machine tools are applicable for most of the sub-categories, including machining centers and lathes. This gives a global market size of 60% of the machine-tools produced.
Both machine tool and machine tool processes has received extensive research in the area of process improvement, with little been done on machine condition monitoring to predict malfunction and less on energy optimization. Most of the research has been based around known applications in temperature and vibrations. The use of these technologies has been limited to use during the engineering phase, testing and final machine assembly.
Currently condition monitoring has to be done selectively and the potential economic savings have to be analyzed carefully. The two main factors that have to be considered: the reduction in production losses due to breakdowns and the maintenance costs (replacement parts and labour). Under these criteria there are two critical elements in a machine tool: the spindle and the linear guides.
Machine spindle defects are responsible for the most common and cost-intensive downtimes in machine-tools. Previous analysis done by consortium members indicates that current signal analysis can be used to detect failures in the driven loads, for example: Load bearing problems, gear tooth damage, gear shaft unbalance, etc.
In the case of linear guides the cost of preventive maintenance is high and it is essential to extend the maintenance period but without risks, use of predictive maintenance technologies would ensure extent operation and minimize the maintenance cycle. This is especially relevant if we consider the actual trend for European machine tool industry to produce larger machines, where these maintenance operations are costly and time consuming due to the need to move large parts.
To prevent failures typical of linear movement axis, the machine builders integrate different mechanical strategies like electrically preloaded paired gears with which they almost overcome the nonlinearities that contributes to mechanical positioning errors like backlash, compliances and friction. The first one actually is solved by paired gears that hydraulically or electrically maintain pressure on the pinion avoiding backslash over the linear gears sculpted on guides.
These non-linear effects are quite well controlled during the life of the machine and if advances are required it should come through improvements in electrical regulation of motors. Friction is more critical since it depend on the correct lubrication process. The linear axis of machines that are controlled by these processes are automatically done, and the access for lubrication does not require normally manual (human) action unlike the case of grease on gear boxes of some type of spindles. With little need for manual greasing, which in turn reduces visual inspection, many problems can arise because an extensive use or under a failure of the automatic mechanism. These failures may be detected through the increase on motor power consumption and load profile. The lack of lubrication can produce new defects in balls, needles, gears... of the moving parts involved in machine movements. These may lead to wear in the gears which will produce vibrations on the moving structural parts of the machine as the columns, and this will require a human readjustment of the linear axis. The prediction of this type of failures is also able based on power monitoring and load profiling.
Considering this analysis, it seems a good strategy to center Power-OM in motor spindle and linear movements. However it can be seen that the technology developed in this sense would have high potentials across industry types as rotational and lineal movements are widely used in industry: cranes, conveyors and, in general, many manipulation devices and production machines with other purposes.
OBJECTIVES
The aim for Power-OM is to use the energy consumption monitoring and profiling, in an easy to implement condition based maintenance (CbM) technique, and manage it as a mechanism to improve the overall business effectiveness, under a triple perspective:
1. Optimizing maintenance strategies based on the prediction of potential failures and guiding the planning of maintenance operations: to schedule maintenance operations in convenient periods and avoid unexpected equipment failures.
2. Operation: Managing the energy as a production resource and reduce its consumption
3. Product reliability: Providing the machine tool builder with real data about the behaviour of the product and their critical components
The main idea behind Power-OM is not to achieve the best CbM platform, is to get the most cost effective and easy to implement.
The specific industrial objectives established from the beginning of the project were:
1. Avoid 75% of unexpected equipment failures in the case of spindles and linear guides. This can have an impact between 3-10% in production system availability depending of the production dependencies.
2. The application of the new maintenance strategy should not require extra costs. If some investment is required for the introduction of predictive maintenance technology this should be compensated by a reduction of the cost of planned or preventive maintenance.
3. Regarding the energy consumption, the objective is to reduce it in a 5%.
4. For product reliability, increase the MTBF 25% for spindles and linear guides. In the long term, this value should be higher considering the product innovation derived from the information received by the machine tool developer about the real behaviour of these components
Project Results:
The Exploitable Results coming out from the project are:
1-CANDTA for Genior Modular (ARTIS, FAGOR)
2-Vibration and Acceleration Transducer (ARTIS)
3-Offline Process Recorder (ARTIS)
4-Development Environment (FAGOR)
5-Data Logger (FAGOR)
6-Machine-Tool health assessment (TEKNIKER)
7-IntelliEnergy Diagnostic (Local) (MONITION)
8-KASEM for Machine-Tool (PREDICT)
9-Machine-Tool knowledge model (PREDICT)
10-Fleet-wide monitoring and management services (PREDICT)
11-IntelliEnergy Diagnostic (Remote) (MONITION)
12-Health assessment and fleet-wide management (GORATU)
A detailed description of the main S&T results/foregrounds is provided in the PDF document ("Final publishable summary report").
Potential Impact:
(1) MARKET OVERVIEW
The target market for Power-OM results is the machine tool industry although final users will be the end the users of these machines. The market overview is based, mainly, on a CECIMO study on the competitiveness of the European machine tool industry (2011).
In Europe, machine tool industry is one of the most globally competitive sectors. More than one third of the world machine tool production are generates in Europe and half of world exports originates from Europe.
The main driving force of the industrialisation of a country or a region is machine tools. They are the foundation of development and progress of the economy. Without machine tools there will be no industrialisation and economic progress.
The world’s most advanced and largest machine tool production base is owned by Europe. CECIMO countries who cover 98% of Europe’s machine tool productions shared 39% global machine tool production in 2013. (CECIMO Magazine, Fall 2014) Though Europe is the world’s largest manufacturer of machine tools and the leader of industry’s technology, recently this has been challenged with the emergence of the Asian countries. It is because of the Asian country’s global economic powers and their motivation to invest in their own machine tool industry development because of the interest in developing their local manufacturing base. A strong machine tool industry allows a nation to take control of its own economic development.
Also the global economic crisis made a fall on Europe machine tool industry as order intake collapsed. Since then Europe lost their importance as a market for machine tools while Asian economies stand up stronger than Europe and continue to develop their machine tool industry.
The shift of machine tool consumption to other regions of the world which are too far to reach for some European SMEs and companies from emerging countries which receive strong support from their governments and having large domestic market are challenging European exporters in their home markets are the two challenges that European machine tool industry facing today. For these Europe need to rebuild the economy and need to run economic machinery and produce new products and services with savings in natural resources and energy, master new advance production technologies.
Impacts of the global economic crisis on the European machine tool manufacturers:
• Market shares have been re-organised and market have shifted to emerging counties
• Small companies have become even smaller and big companies have become even bigger
• Local market has lost significant weight because of the trouble in the demand from traditional domestic markets after the crisis
• The weakening of the European market has a negative impact on R&D and innovation and end-users at proximity drive the demand for new solutions- A certain number of companies did go through hard times and were acquired by other builders, both European and non-European
• Foe two years crisis forced to slow down R&D efforts
• In Europe, overall a low rate of company failure was observed
• Due to rise in raw materials, intermediary components and energy prices, huge cost pressures and price rises after the crisis was observed
• Carefulness of the capital expenditure programs of European customers after the crisis
• Due to a decline of industry results, finance accessing difficulties have multiplied
• Banks are more cautious about giving credit to SMEs
• Most companies were able to keep their skilled workforce while some companies lost their workforce by 20%.
The way of Europe machine tool manufacturers react to the crisis:
• Cost cutting to cope with vanishing income
• Adjustments in production capacity
• Flexible working hours
• Adoption of solutions to increase productivity
• Increase focus on emerging markets
• Concentra on more customer-oriented business strategies
• Increase automation and take new tools in use to tackle the labour shortage threat in the long-term
After the global economic crisis European machine tool industry had to face to a new business environment with the challenging growth of the Asian machine tool industry.
For a long time Europe, Japanese, American and Taiwan machine tool manufacturers have controlled high-end machine tool market. But today manufacturers from other Asian countries such as China and Korea have come to challenge to those past big players in the machine tool industry.
Because of the new technologies searches, customer requirements are changing quickly. Other than the new technological searches customer requirements change because of the climate change, environmental degradation. These make changes in machine tool buyers’ market. These changes may different region to region or location to location.
During the fourth quarter of 2014 machine tool total orders index recorded an increase. It was 18% increase compared to the third quarter of the year with including an increase of 16% of foreign orders and 36% domestic orders indexes. Also compared to the fourth quarter of previous year (2013) it was a 15% increase including increases of 18% foreign orders and 11% domestic orders indexes.
(2) SWOT ANALYSIS TO EU MACHINE TOOL INDUSTRY AND POWER-OM CONTRIBUTION
Strengths:
• High-end technology
• High skilled labour
• Accumulated engineering experience
• Innovation capacity
• The existence of excellent downstream suppliers in Europe
• Vocational training
• Multilingualism
• Public R&D resources
• Customer intimacy
Weaknesses:
• Small enterprise dimension to attack global market
• Administrative burdens, restrictions, tight regulations
• Difficult access to Asian markets
• Limited access to finance (total risk on owner in SMEs)
• Not sufficient supply of labour
Opportunities:
• Strong European image/brand
• Customer intimacies (develop customer services and turn it into value. Customers do not have their own people to develop production solutions)
• Shift towards green economy
• Rising demand in China
• Further EU enlargement
• Global economy growth – rising technical requirements
• Automations
• Free trade agreements
Threats:
• Chinese competition
• Shrinking of manufacturing industry in China
• Moving of the European manufacturing to Asia
• Access to materials
• New low cost competitors from Taiwan first and then from China
• Limited interest of students in engineering
• Subcontracting network loses competitiveness
• IPR infringements
• Subsidizing non-EU competitor investors with EU public money
• Ageing population, early retirement
• Financial system risks
Power-OM results are aligned with most of the opportunities identified in the SWOT analysis, with contributions to the:
• European machine tool image/brand
• Development of customer services and turn it into value.
• Shift towards green economy
(3) IMPACT
Impact 1 - Increase the Overall Equipment/Business Effectiveness by a factor of (5%):
The major impact of the application of Power-OM is in preventing unexpected equipment failures and assure a production availability because a better planning of predictive maintenance operations:
Maintenance cost (without consider the production downtime) will be in the same order, although a small reduction is foreseen. What happens is that the cost to repair is reduced but predictive inspection cost increase.
But the success in detecting and repairing potential failures not only prevents failure, but also contributes to:
• More efficient plant operation, and more consistent quality, obtained by matching the rate of output to the plant condition
• Improve service level and customer satisfaction through timely deliveries.
• Helps to ensure plant operation at optimum efficiency and in so doing minimizes energy usage.
• More effective negotiations with the equipment manufacturers, backed up by systematic measurements of plant condition
• The opportunity to specify and design better plant in the future
Impact 2 - Reduce energy costs (5%):
There is a recent Directive of the European Parliament on Energy using Products [Directive 2009/125/EC] to establish a framework for the setting of eco-design requirements for energy-using products. The European Commission has publish a working plan [Working plan for 2009-2011 under the Ecodesign Directive] with an indicative list of energy-using product groups which will be considered priorities for the adoption of implementing measures, and machine tools is as one of the ten product groups included.
Machine tool sector is moving in this sense. As an example this is the track of German initiatives:
• 2008: The German Machine Tool Builder Association (VDW) developed the label “Blue Competence”.
• 2009: Presentation of the label „Blue Competence“ at the EMO.
• 2010: Funding of the German innovation platform “Resource Efficiency in Production”(German: “Effizienzfabrik”), founded by the German Federal Ministry of Education and Research (BMBF).
• 2010: 15 companies adressed „Blue Competence“ at the METAV (additionaly symposium “Die energieeffiziente Werkzeugmaschine”) und 27 companies at the AMB.
All this means that energy saving measures is getting more relevance, and especially in machine tool sector for metal working production, that demands the 15% of the whole electric power consumption (German statistics).
Due to increased market prices for electrical energy, it is expected that the energy related costs will increase by 76 % from 4.3 % in 2003 to 7.6 % in 2013 in relation to the total annual costs of producing companies.
50% of companies in mechanical engineering consider regardless of the size of the company the potential for energy savings in the production to at least 10%. Mechanical engineering is thus in the first third of manufacturing firms that see a very high potential to reduce energy costs. Other branches of manufacturing industry that use machine tools see some significant energy savings potentials as well. Furthermore, it is also stated that 61 % of asked companies realized energy saving measures in general in the last three years and 26 % of these companies are currently implementing energy saving measures. In total, 87 % of the surveyed companies were or are realizing those measures including not only in the production but also heating systems and insulation of buildings. The survey of this study reveals that for 87.5% of manufacturers the energy consumption of designed metal working machine tools is relevant and for 62.5% the energy consumption of machine tool production. The results show further that 83.3% intend to plan measures to diminish energy consumption of designed machine tools and 71.4% of the machine tool production. 85.7% of machine tool manufacturers claim to already offer energy saving modes and modules such as sleep and stand-by modes or the use of synchronous motors. However, only 7.2% of customers actually demand energy saving modes or modules.
Impact 3 - Improve SMEs competitiveness:
Power-OM will contribute proactively to the SMEs competitiveness (users, components, solutions, and service providers). Power-OM is a project leaded by SMEs and with the aim to benefit to SMEs. A large company as ARTIS has been also involved, because a leading company like this, working with most of the CNC OEMs and machine tool producers, will pull significantly the business of the SME involved in the consortium.
Considering the project partners and their business sectors, these are the expected impacts:
• PLC/CNC Control (FAGOR): Power-OM contributes to their positioning in relation with the competence. The solution must be open to be used or plug-able to other controls. Control providers, in general, are “end users” of Power-OM technology, although they normally are not SMEs.
• Machine-tool developer (GORATU): Power-OM contributes with the incorporation of advanced features in their machines. Machine tool builders, in general, a SME dominated business in Europe, are also “end users” of Power-OM technology.
• eMaintenance infrastructure providers (PREDICT): With a new solution offered to a specific market segment, the production systems, will increase its own business.
Further to the project partners, the results of the project will impact in the SME competitiviness; By one hand in the machine tool producers, adding innovative services to their machines, and of course, end users of these production systems, as has been evaluated before.
Finally, Power-OM will contribute to the generation and consolidation of services companies in the maintenance business. These companies are usually SMEs.
Impact 4 - Extend the application to other production system:
There are other machines and mechatronic systems where Power-OM could be used and exploited; In general in all the devices where electric motors are used. Of course the systems to be considered should be significant in terms of value, availability requirements, etc. Some significant example could be machines used in steel products processing, cranes, etc. Different statistics indicates that electric motors are responsible for almost 70 percent of all energy consumed in industrial applications.
(4) EXPLOITATION OF RESULTS
ARTIS
ARTIS GmbH is a global leader in the areas of tool and process monitoring for metal cutting. There are more than 15,000 systems currently in operation, mainly in the automotive and aerospace industries, from single part to large series production. Since 2008, ARTIS belongs to the MARPOSS Group, the specialist for all kinds of metrology in production who provides an international sales and service organization.
There are new exploitable results developed during POWER-OM with potential to become products:
• Vibration and Acceleration Transducer
• CANDTA for Genior Modular
• OPR - Offline Process Recorder
FAGOR
FAGOR will benefit from the Power-OM in two different, complementary ways. First, the development of features that open the CNC to real time third party tasks and their integration in the whole system , opens a new market segment, that of general automation and process control, but with the added experience in coordinate motion of machine axis, kinematics transformations and smooth path generation and jerk control. Second, the interoperability with external sensor interface devices will position the CNC offer in the high end machine tool offer, ahead of emergent competitors from Asia. The proper monitoring and maintenance is key to the sustainability and reliability of machine equipment and to a better efficiency and less power consumption, issues that have increasingly importance in western countries where FAGOR wants to keep as one of the leading European CNC manufacturers.
Specific results to be exploited by FAGOR are:
1- A software feature (option) for the CNC FAGOR8070/8065 that includes:
• Template for visual studio development or makefile for mingw compiler
• Examples for Real Time algorithms to be included in the CNC’s call path
• Filters for debugging information extraction and library for user’s data access in C.
• Tools adaptation in the CNC to access user’s data.
FAGOR will sell this as an option to potential customers (engineering companies and some machine tool manufacturers). Some assistance could be included in the form of hours of R&D people.
2- FAGOR CNC Data Logger - Recorder
Software option addressed to Machine Tool Builders and End Users. On-going requirements phase for the final product, to be sold as a software option.
PREDICT
PREDICT expect to exploit project results with Power-OM partners as part of an integrated solution or as part of PREDICT’s eMaintenance platform offering. Some added value services exploitable by PREDICT would be:
• KASEM for Machine Tool
• Machine Tool Knowledge Model
• Fleet-Wide Monitoring and Management Services
PREDICT’s objectives are to win new markets with new activities in the next years. Power-OM new products will be an important part of this turn-over. PREDICT has contractual relationships with Power-OM partners and they are organizing sale process.
MONITION
As Monition Ltd. provides expert services in the field of condition monitoring, Assets reliability and Energy management, the Power OM project will allow Monition to expand its service portfolio and thus gain further custom, especially in the manufacturing area.
Regarding the IntelliEnergy Diagnostic software module:
• Monition will continue to collaborate with the existing consortium members to develop an integrated power solution to enhance system capabilities.
• It is intended to partner with system integrators with current market share and dedicated sector expertise to speed route to market.
• The system will be developed into a general cross sector platform for use with general manufacturing industry. The concept and current deliverable is extremely adaptable to these applications.
• The fault tree diagnostic will be developed in an AI based decision module for use on a decision integrator across industry sectors.
• The system will be exploited as a service tools for installation and configuration and revenue stream will cover licencing to direct selling, also providing the platform for monition Core Reliability services.
TEKNIKER
TEKNIKERS as owner of the Machine Tool Health Assessment module, will continue the collaboration with some partners in the project, and will use this as this background in projects with other Machine-tool manufacturers.
Added to this, there is other possibilities for the exploitation of this background through other distribution channels, such as:
• Companies already present in this business segment (sensors & monitoring).
• CNC manufacturers.
GORATU
Because of the global market competition, GORATU has moved to produce customized large size milling machines and lathes.
The objective of this product is to improve the availability of GORATU milling machines by means of improving maintenance strategies.
The strategy for GORATU is:
To include the embedded software in the NC control that monitors the working conditions of the new machines.
Promote new maintenance services. The concept to push is “proactive maintenance” based on:
• Main maintenance operation remainders based on the use of the machine
• Early warning of main components performances
• Customized reports availability
(5) SCIENTIFIC DISSEMINATION
Papers published:
Green Condition based Maintenance - an integrated system approach for health assessment and energy optimization of manufacturing machines. Conference on Condition Monitoring and Machinery Failure Prevention Technologies. June 2013 in Krakow, Poland.
New technologies to optimize reliability, operation and maintenance in the use of Machine-Tools. EuroMaintenance Congress, 2014, Helsinki, Finland (clustered session with FoF projects in maintenance).
Health and Performances Machine Tool Monitoring Architecture. E-maintenance conference, under the topic Integration with Prognostic Health Management. June 2014, Luleå, Sweden.
Motor current signature analysis for gearbox health monitoring: Experiment, signal analysis and classification. PHM Europe Conference, under the topic Condition Monitoring in Rotating Machinery. July 2014, in Nantes, France.
Aggregation of electric current consumption features for extraction of maintenance KPIs. Maintenance Performance Measurement and Management (MPMM) Conference, from 4th to 5th of September 2014 in Coimbra, Portugal
Context Driven Remaining Useful Life Estimation. 3th International Conference in Through-life Engineering Services, from 4th to 5th of November 2014, in Cranfield, United Kingdom.
There are other two papers planned to be published through 2015:
• Prognosis of machine tools: A context awareness approach. Journal of Intelligent Manufacturing. Authors: LTU.
• Motor current signature analysis, using wavelets for speed transient analysis to estimate health status in spindles. IEEE transactions on Industry Applications. Authors: TEKNIKER.
(6) INDUSTRIAL DISSEMINATION
The industrial dissemination which is focus to industrial audiences such as machine tool manufacturers, maintenance services providers, OEMs, etc. is coordinate by MONITION Ltd. As part of this, researches has been carried out to identify the industrial audiences and their behaviours, the future trade fairs, events and publications oriented to the machine tool industry. Also a press release, a set of flyers and a poster has designed to inform about the project to its audience.
As mentioned above, as a part of the Task 9.1 in WP 9 in the project, PowerOM flyers were designed to inform about the project to the audiences. These were designed in five different sizes/types and in four different designs to fit in different industries. They have been distributed in five different sizes/types: A3, A3 – Regular - 2 Panel, A4, A4 – Regular - 2 Panel, A4 – Roll - 3 Panel.
Different industries:
• Aerospace and Aeronautics Industry
• Automotive Industry
• General Industries
• Vehicle Industry (Aerospace and Aeronautics, Automotive, Ship, Railway)
MONITION sent the press release to several magazines (online/printed) under the title “Power-Consumption Monitoring to Raise Machine Reliability” highlighting:
• American Machinist Website: http://americanmachinist.com/qc-and-inspection/power-consumption-monitoring-raise-machine-reliability
• Industrial Supply Asia website: http://www.industrialsupply.com.cn/EN/Co/?CID=12&AID=219
Along with the press release, the PowerOM poster also sent to the magazines. The main obstacle when trying to publish the press release is that the magazines aren’t willing to publish them for free. This has effected for the minimal response in publishing the press release.
Other than publishing the press release in the magazines MONITION is working on sending it to Machine Tool Manufactures, Machine Tool End Users and to industry specific societies (internet societies) though LinkedIn. Also MONITION distributed the flyers and poster through emails to several machine tool builders and users as a part of making aware about the project to the industry related people.
GORATU, FAGOR, TEKNIKER had a special action in the BIEMH 2014 http://www.biemh.com/en/ the international machine tool fair hold in Bilbao 30May-04 June. It was produced a brochure in Spanish (attached, later translated into Italian and English languages) and 600 paper copies were distributed in the boots of GORATU, FAGOR and TEKNIKER.
At the end of the project, a new poster was produced including as contents the main exploitable results
Power-OM Product Launch Seminar: ARTIS GmbH organised a successful product launch seminar on 24th of March 2015. The objective of the seminar was to share with industry vision, concepts, prototypes and potential products coming out from Power-OM. The seminar included demonstrations in ARTIS Lab. The relevant end users from the automotive sector and representatives from machine tool manufacturing OMEs attended to this seminar. More information about this can be found in project website.
XX Congress of Machine Tools and Manufacturing Technologies: TEKNIKER and FAGOR presented Power-OM project in the XX Congress of Machine Tools and Manufacturing Technologies which was held on 10-12 of June 2015 in San Sebastian. This event was organised by Spanish Association of Machine Tools, accessories, components and tools (AFM):
• TEKNIKER presented the concept of Machine 4.0. The implementation of this concept means between others, the development of new services based on the collaboration between machine tool manufacturer and machine users to optimise the uptime. Aligned with this objective, Power-OM results were presented.
• FAGOR presentation was about Tuning 4.0 and Services 4.0. Among others, the possibility to implement a Condition Based Monitoring strategy based on the fingerprint concept and FAGOR CNC data logger was presented.
(7) OTHER DISSEMINATION ACTIONS
Workshop on Impact of the Factories of the Future PPP – Brussels 11-12 March 2013:
Added to Power-OM, the other two projects were:
• iMain - A Novel Decision Support System for Intelligent Maintenance
• Supreme - SUstainable PREdictive Maintenance of manufacturing Equipment
Workshop on Impact of the Factories of the Future PPP – Brussels, 25-26 March 2014:
Power-OM was clustered in the Area 2 about “Maintenance, repair, re-use”. In this sense one goal was to merge related projects from different calls:
• Methodologies and tools for the sustainable, predictive maintenance of production equipment (FoF.NMP.2012-2)
• Innovative strategies for renovation and repair in manufacturing systems (FoF.NMP.2013-8)
• Innovative re-use of modular equipment based on integrated factory design (FoF.NMP.2013-2)
• Intelligent production machines and 'plug-and-produce' devices for system adaptivity (FoF.NMP.2012-3)
The expected impacts of the supported area of the projects are:
• Increase availability of production systems & OEE.
• Energy consumption reduction (10%)
• Reduction of around 20% of renovation and repair costs
• At the end-of-life stage, contribution towards a 80-100% reuse of production system components in new life cycles
• Cost reduction of around 30% due to re-use of existing modular equipment when setting-up production systems for new product variants
• Renovation of outdated plants and structures. Safe production sites
Workshop on Impact of the Factories of the Future PPP – Brussels, 29-30 April 2015:
Representatives of over 150 FoF projects were there. Power-OM project was represented again in the area of “Maintenance, Repair and Reuse”, under the theme of “Environmental sustainability”. Added to Power-OM, the clustered projects were the same as in previous edition: IMAIN, SUPREME, REBORN, WHITER, SELSUS, T-REX and EASE-R3.
From all the clustered projects, four of them (Power-OM, IMAIN, T-REX and EASE-R3) focus on maintenance and new services in machine-tool business.
Among these collaboration activities, the specific cluster action Co-FACTOR was included as a relevant one. Co-FACTOR is clustering six different running FoF projects: I-RAMP3, ReBorn, SelSus, T-REX, INTEFIX and Power-OM. The common ground is the development of ‘smart components in manufacturing’ that can be also linked to Cyber-Physical Systems (CPS), as main technologies to support the smarter production systems.
(8) FUTURE ACTIVITIES
Exhibition during next summer from 30th May to 4th June 2016; allocated in Bilbao, Spain. This is a “gathering event to make business”, where “Smart Technology for Smart Solutions” is the main topic. Goratu, Fagor and Tekniker will be involved.
List of Websites:
Public web page:
www.power-om.eu
Contact details:
Aitor Alzaga
aitor.alzaga@tekniker.es
The list of participants and their web pages links are available through the project website: http://power-om.eu/consortium.
European manufacturers of machine tools are positioned in the manufacture of high value-added products. The fact that customers buy machines with high added value means that these machines are used in critical processes and therefore expect machines free of failures. In these machines, spindle faults are responsible for the most common and cost-intensive downtimes in machine-tools.
The normal strategy to keep these production systems in good conditions is to apply preventive maintenance practices and complement it with a supportive workforce “reactive” in the case of clearly detected malfunctions. This impact on quality, cost and in general, productivity. Added to this, the uncertainty of machine reliability at any given time, also impacts on product/production delivery times.
The use of intelligent predictive technologies could contribute to improve the situation, but these techniques are not widely used in the production environment. Sensors and other monitoring techniques required for the production environment are not so standard and require costly implementations.
Project has research in the development of those mechanisms that can make possible the implementation of a pro-active maintenance strategy:
• Machine tool health assessment using the Electric Signature Analysis technique. This has been applied to the most critical components (spindle and linear axis) that are responsible of more than 80% of the idle time.
• Machine working condition monitoring
• The collection and analysis of data at the fleet level
The technology developed is easy to implement and little intrusive, allowing the machine tool manufacturer:
• Be more pro-active regarding potential problems that the client may have,
• Conduct a faster and more accurate diagnosis,
• Provide recommendations for the future; for example, the spindle head which suits better the customer type of work.
This is something could be offered by the machine tool manufacturer as a standard feature. The efforts made by the manufacturer would be rewarded for its ability to anticipate problems and respond to customers more efficiently and orderly. Moreover, the machine manufacturer would have valuable information regarding the behaviour of the machine in relation to the use that would, among other things, future product enhancements.
The results can be categorized in two groups:
• Components that can be embedded in the machine as data loggers to save working conditions and to implement the finger print concept based on current signal capture and its analysis.
• e-Maintenance platform to aggregate the information coming from the fleet of machines. This includes the knowledge model to facilitate heterogeneous knowledge (i.e. data, information, results) retrieval and sharing on the basis of the monitored units composing the fleet. Final objective is to make periodic assessment of performance indices (health, energy consumption and other KPIs). The system generates also pro-active alarm when a drift in the machine tool performance or some component degradation is detected. The knowledge/data found in the fleet help also in the predictive diagnostic of the fault.
Project Context and Objectives:
PROJECT CONTEXT
Production systems deteriorate with the usage and age. The normal strategy to keep them in good conditions is to apply preventive maintenance practices, with a supportive workforce “reactive” in the case of clearly detected malfunctions or machine breakdowns. All these have an impact on quality, cost and in general, productivity. Added to this, the uncertainty of machine reliability at any given time, also impacts on product/production delivery times. It is known also that a worn-out or incorrectly assembled mechanism has higher energy consumption.
The use of intelligent predictive technologies and tools could contribute to improve the situation; it has been proven that deployment of these tools and techniques can detect malfunctions or potential breakdowns, and help and guide an anticipated solution. However the obvious of the advantages of a predictive strategy and techniques are not widely used in the production environment. There are many reasons for this, one of the main obstacles is providing a sound cost-benefit analysis for the business. Often sensors and monitors that are required for the production environment are non standard. Most applications that require a solution to particular problems are solved case-by-case basis with sensors have to be retro fitted to existing machines, which means the implementation is costly and requires machines down time for access and often ongoing monitoring making the cost benefits harder to quantify. Added to this, for some processes, retro fitting of addition monitoring sensors/devices is not possible due to machine configuration, process constraints and I.T. integrity concerns. Even machine integrated solutions are not installed widely at machine delivery phase. The monitoring requirement at machine order phase is often not a must requirement, but a might requirement, which leads to a cost reduction opportunity often used in the purchasing department.
Machine tool critical components:
From all the machines produced, machine tools are the most significant homogeneous group, in terms of value it could be up to 20%. The predictive strategies developed for machine tools are applicable for most of the sub-categories, including machining centers and lathes. This gives a global market size of 60% of the machine-tools produced.
Both machine tool and machine tool processes has received extensive research in the area of process improvement, with little been done on machine condition monitoring to predict malfunction and less on energy optimization. Most of the research has been based around known applications in temperature and vibrations. The use of these technologies has been limited to use during the engineering phase, testing and final machine assembly.
Currently condition monitoring has to be done selectively and the potential economic savings have to be analyzed carefully. The two main factors that have to be considered: the reduction in production losses due to breakdowns and the maintenance costs (replacement parts and labour). Under these criteria there are two critical elements in a machine tool: the spindle and the linear guides.
Machine spindle defects are responsible for the most common and cost-intensive downtimes in machine-tools. Previous analysis done by consortium members indicates that current signal analysis can be used to detect failures in the driven loads, for example: Load bearing problems, gear tooth damage, gear shaft unbalance, etc.
In the case of linear guides the cost of preventive maintenance is high and it is essential to extend the maintenance period but without risks, use of predictive maintenance technologies would ensure extent operation and minimize the maintenance cycle. This is especially relevant if we consider the actual trend for European machine tool industry to produce larger machines, where these maintenance operations are costly and time consuming due to the need to move large parts.
To prevent failures typical of linear movement axis, the machine builders integrate different mechanical strategies like electrically preloaded paired gears with which they almost overcome the nonlinearities that contributes to mechanical positioning errors like backlash, compliances and friction. The first one actually is solved by paired gears that hydraulically or electrically maintain pressure on the pinion avoiding backslash over the linear gears sculpted on guides.
These non-linear effects are quite well controlled during the life of the machine and if advances are required it should come through improvements in electrical regulation of motors. Friction is more critical since it depend on the correct lubrication process. The linear axis of machines that are controlled by these processes are automatically done, and the access for lubrication does not require normally manual (human) action unlike the case of grease on gear boxes of some type of spindles. With little need for manual greasing, which in turn reduces visual inspection, many problems can arise because an extensive use or under a failure of the automatic mechanism. These failures may be detected through the increase on motor power consumption and load profile. The lack of lubrication can produce new defects in balls, needles, gears... of the moving parts involved in machine movements. These may lead to wear in the gears which will produce vibrations on the moving structural parts of the machine as the columns, and this will require a human readjustment of the linear axis. The prediction of this type of failures is also able based on power monitoring and load profiling.
Considering this analysis, it seems a good strategy to center Power-OM in motor spindle and linear movements. However it can be seen that the technology developed in this sense would have high potentials across industry types as rotational and lineal movements are widely used in industry: cranes, conveyors and, in general, many manipulation devices and production machines with other purposes.
OBJECTIVES
The aim for Power-OM is to use the energy consumption monitoring and profiling, in an easy to implement condition based maintenance (CbM) technique, and manage it as a mechanism to improve the overall business effectiveness, under a triple perspective:
1. Optimizing maintenance strategies based on the prediction of potential failures and guiding the planning of maintenance operations: to schedule maintenance operations in convenient periods and avoid unexpected equipment failures.
2. Operation: Managing the energy as a production resource and reduce its consumption
3. Product reliability: Providing the machine tool builder with real data about the behaviour of the product and their critical components
The main idea behind Power-OM is not to achieve the best CbM platform, is to get the most cost effective and easy to implement.
The specific industrial objectives established from the beginning of the project were:
1. Avoid 75% of unexpected equipment failures in the case of spindles and linear guides. This can have an impact between 3-10% in production system availability depending of the production dependencies.
2. The application of the new maintenance strategy should not require extra costs. If some investment is required for the introduction of predictive maintenance technology this should be compensated by a reduction of the cost of planned or preventive maintenance.
3. Regarding the energy consumption, the objective is to reduce it in a 5%.
4. For product reliability, increase the MTBF 25% for spindles and linear guides. In the long term, this value should be higher considering the product innovation derived from the information received by the machine tool developer about the real behaviour of these components
Project Results:
The Exploitable Results coming out from the project are:
1-CANDTA for Genior Modular (ARTIS, FAGOR)
2-Vibration and Acceleration Transducer (ARTIS)
3-Offline Process Recorder (ARTIS)
4-Development Environment (FAGOR)
5-Data Logger (FAGOR)
6-Machine-Tool health assessment (TEKNIKER)
7-IntelliEnergy Diagnostic (Local) (MONITION)
8-KASEM for Machine-Tool (PREDICT)
9-Machine-Tool knowledge model (PREDICT)
10-Fleet-wide monitoring and management services (PREDICT)
11-IntelliEnergy Diagnostic (Remote) (MONITION)
12-Health assessment and fleet-wide management (GORATU)
A detailed description of the main S&T results/foregrounds is provided in the PDF document ("Final publishable summary report").
Potential Impact:
(1) MARKET OVERVIEW
The target market for Power-OM results is the machine tool industry although final users will be the end the users of these machines. The market overview is based, mainly, on a CECIMO study on the competitiveness of the European machine tool industry (2011).
In Europe, machine tool industry is one of the most globally competitive sectors. More than one third of the world machine tool production are generates in Europe and half of world exports originates from Europe.
The main driving force of the industrialisation of a country or a region is machine tools. They are the foundation of development and progress of the economy. Without machine tools there will be no industrialisation and economic progress.
The world’s most advanced and largest machine tool production base is owned by Europe. CECIMO countries who cover 98% of Europe’s machine tool productions shared 39% global machine tool production in 2013. (CECIMO Magazine, Fall 2014) Though Europe is the world’s largest manufacturer of machine tools and the leader of industry’s technology, recently this has been challenged with the emergence of the Asian countries. It is because of the Asian country’s global economic powers and their motivation to invest in their own machine tool industry development because of the interest in developing their local manufacturing base. A strong machine tool industry allows a nation to take control of its own economic development.
Also the global economic crisis made a fall on Europe machine tool industry as order intake collapsed. Since then Europe lost their importance as a market for machine tools while Asian economies stand up stronger than Europe and continue to develop their machine tool industry.
The shift of machine tool consumption to other regions of the world which are too far to reach for some European SMEs and companies from emerging countries which receive strong support from their governments and having large domestic market are challenging European exporters in their home markets are the two challenges that European machine tool industry facing today. For these Europe need to rebuild the economy and need to run economic machinery and produce new products and services with savings in natural resources and energy, master new advance production technologies.
Impacts of the global economic crisis on the European machine tool manufacturers:
• Market shares have been re-organised and market have shifted to emerging counties
• Small companies have become even smaller and big companies have become even bigger
• Local market has lost significant weight because of the trouble in the demand from traditional domestic markets after the crisis
• The weakening of the European market has a negative impact on R&D and innovation and end-users at proximity drive the demand for new solutions- A certain number of companies did go through hard times and were acquired by other builders, both European and non-European
• Foe two years crisis forced to slow down R&D efforts
• In Europe, overall a low rate of company failure was observed
• Due to rise in raw materials, intermediary components and energy prices, huge cost pressures and price rises after the crisis was observed
• Carefulness of the capital expenditure programs of European customers after the crisis
• Due to a decline of industry results, finance accessing difficulties have multiplied
• Banks are more cautious about giving credit to SMEs
• Most companies were able to keep their skilled workforce while some companies lost their workforce by 20%.
The way of Europe machine tool manufacturers react to the crisis:
• Cost cutting to cope with vanishing income
• Adjustments in production capacity
• Flexible working hours
• Adoption of solutions to increase productivity
• Increase focus on emerging markets
• Concentra on more customer-oriented business strategies
• Increase automation and take new tools in use to tackle the labour shortage threat in the long-term
After the global economic crisis European machine tool industry had to face to a new business environment with the challenging growth of the Asian machine tool industry.
For a long time Europe, Japanese, American and Taiwan machine tool manufacturers have controlled high-end machine tool market. But today manufacturers from other Asian countries such as China and Korea have come to challenge to those past big players in the machine tool industry.
Because of the new technologies searches, customer requirements are changing quickly. Other than the new technological searches customer requirements change because of the climate change, environmental degradation. These make changes in machine tool buyers’ market. These changes may different region to region or location to location.
During the fourth quarter of 2014 machine tool total orders index recorded an increase. It was 18% increase compared to the third quarter of the year with including an increase of 16% of foreign orders and 36% domestic orders indexes. Also compared to the fourth quarter of previous year (2013) it was a 15% increase including increases of 18% foreign orders and 11% domestic orders indexes.
(2) SWOT ANALYSIS TO EU MACHINE TOOL INDUSTRY AND POWER-OM CONTRIBUTION
Strengths:
• High-end technology
• High skilled labour
• Accumulated engineering experience
• Innovation capacity
• The existence of excellent downstream suppliers in Europe
• Vocational training
• Multilingualism
• Public R&D resources
• Customer intimacy
Weaknesses:
• Small enterprise dimension to attack global market
• Administrative burdens, restrictions, tight regulations
• Difficult access to Asian markets
• Limited access to finance (total risk on owner in SMEs)
• Not sufficient supply of labour
Opportunities:
• Strong European image/brand
• Customer intimacies (develop customer services and turn it into value. Customers do not have their own people to develop production solutions)
• Shift towards green economy
• Rising demand in China
• Further EU enlargement
• Global economy growth – rising technical requirements
• Automations
• Free trade agreements
Threats:
• Chinese competition
• Shrinking of manufacturing industry in China
• Moving of the European manufacturing to Asia
• Access to materials
• New low cost competitors from Taiwan first and then from China
• Limited interest of students in engineering
• Subcontracting network loses competitiveness
• IPR infringements
• Subsidizing non-EU competitor investors with EU public money
• Ageing population, early retirement
• Financial system risks
Power-OM results are aligned with most of the opportunities identified in the SWOT analysis, with contributions to the:
• European machine tool image/brand
• Development of customer services and turn it into value.
• Shift towards green economy
(3) IMPACT
Impact 1 - Increase the Overall Equipment/Business Effectiveness by a factor of (5%):
The major impact of the application of Power-OM is in preventing unexpected equipment failures and assure a production availability because a better planning of predictive maintenance operations:
Maintenance cost (without consider the production downtime) will be in the same order, although a small reduction is foreseen. What happens is that the cost to repair is reduced but predictive inspection cost increase.
But the success in detecting and repairing potential failures not only prevents failure, but also contributes to:
• More efficient plant operation, and more consistent quality, obtained by matching the rate of output to the plant condition
• Improve service level and customer satisfaction through timely deliveries.
• Helps to ensure plant operation at optimum efficiency and in so doing minimizes energy usage.
• More effective negotiations with the equipment manufacturers, backed up by systematic measurements of plant condition
• The opportunity to specify and design better plant in the future
Impact 2 - Reduce energy costs (5%):
There is a recent Directive of the European Parliament on Energy using Products [Directive 2009/125/EC] to establish a framework for the setting of eco-design requirements for energy-using products. The European Commission has publish a working plan [Working plan for 2009-2011 under the Ecodesign Directive] with an indicative list of energy-using product groups which will be considered priorities for the adoption of implementing measures, and machine tools is as one of the ten product groups included.
Machine tool sector is moving in this sense. As an example this is the track of German initiatives:
• 2008: The German Machine Tool Builder Association (VDW) developed the label “Blue Competence”.
• 2009: Presentation of the label „Blue Competence“ at the EMO.
• 2010: Funding of the German innovation platform “Resource Efficiency in Production”(German: “Effizienzfabrik”), founded by the German Federal Ministry of Education and Research (BMBF).
• 2010: 15 companies adressed „Blue Competence“ at the METAV (additionaly symposium “Die energieeffiziente Werkzeugmaschine”) und 27 companies at the AMB.
All this means that energy saving measures is getting more relevance, and especially in machine tool sector for metal working production, that demands the 15% of the whole electric power consumption (German statistics).
Due to increased market prices for electrical energy, it is expected that the energy related costs will increase by 76 % from 4.3 % in 2003 to 7.6 % in 2013 in relation to the total annual costs of producing companies.
50% of companies in mechanical engineering consider regardless of the size of the company the potential for energy savings in the production to at least 10%. Mechanical engineering is thus in the first third of manufacturing firms that see a very high potential to reduce energy costs. Other branches of manufacturing industry that use machine tools see some significant energy savings potentials as well. Furthermore, it is also stated that 61 % of asked companies realized energy saving measures in general in the last three years and 26 % of these companies are currently implementing energy saving measures. In total, 87 % of the surveyed companies were or are realizing those measures including not only in the production but also heating systems and insulation of buildings. The survey of this study reveals that for 87.5% of manufacturers the energy consumption of designed metal working machine tools is relevant and for 62.5% the energy consumption of machine tool production. The results show further that 83.3% intend to plan measures to diminish energy consumption of designed machine tools and 71.4% of the machine tool production. 85.7% of machine tool manufacturers claim to already offer energy saving modes and modules such as sleep and stand-by modes or the use of synchronous motors. However, only 7.2% of customers actually demand energy saving modes or modules.
Impact 3 - Improve SMEs competitiveness:
Power-OM will contribute proactively to the SMEs competitiveness (users, components, solutions, and service providers). Power-OM is a project leaded by SMEs and with the aim to benefit to SMEs. A large company as ARTIS has been also involved, because a leading company like this, working with most of the CNC OEMs and machine tool producers, will pull significantly the business of the SME involved in the consortium.
Considering the project partners and their business sectors, these are the expected impacts:
• PLC/CNC Control (FAGOR): Power-OM contributes to their positioning in relation with the competence. The solution must be open to be used or plug-able to other controls. Control providers, in general, are “end users” of Power-OM technology, although they normally are not SMEs.
• Machine-tool developer (GORATU): Power-OM contributes with the incorporation of advanced features in their machines. Machine tool builders, in general, a SME dominated business in Europe, are also “end users” of Power-OM technology.
• eMaintenance infrastructure providers (PREDICT): With a new solution offered to a specific market segment, the production systems, will increase its own business.
Further to the project partners, the results of the project will impact in the SME competitiviness; By one hand in the machine tool producers, adding innovative services to their machines, and of course, end users of these production systems, as has been evaluated before.
Finally, Power-OM will contribute to the generation and consolidation of services companies in the maintenance business. These companies are usually SMEs.
Impact 4 - Extend the application to other production system:
There are other machines and mechatronic systems where Power-OM could be used and exploited; In general in all the devices where electric motors are used. Of course the systems to be considered should be significant in terms of value, availability requirements, etc. Some significant example could be machines used in steel products processing, cranes, etc. Different statistics indicates that electric motors are responsible for almost 70 percent of all energy consumed in industrial applications.
(4) EXPLOITATION OF RESULTS
ARTIS
ARTIS GmbH is a global leader in the areas of tool and process monitoring for metal cutting. There are more than 15,000 systems currently in operation, mainly in the automotive and aerospace industries, from single part to large series production. Since 2008, ARTIS belongs to the MARPOSS Group, the specialist for all kinds of metrology in production who provides an international sales and service organization.
There are new exploitable results developed during POWER-OM with potential to become products:
• Vibration and Acceleration Transducer
• CANDTA for Genior Modular
• OPR - Offline Process Recorder
FAGOR
FAGOR will benefit from the Power-OM in two different, complementary ways. First, the development of features that open the CNC to real time third party tasks and their integration in the whole system , opens a new market segment, that of general automation and process control, but with the added experience in coordinate motion of machine axis, kinematics transformations and smooth path generation and jerk control. Second, the interoperability with external sensor interface devices will position the CNC offer in the high end machine tool offer, ahead of emergent competitors from Asia. The proper monitoring and maintenance is key to the sustainability and reliability of machine equipment and to a better efficiency and less power consumption, issues that have increasingly importance in western countries where FAGOR wants to keep as one of the leading European CNC manufacturers.
Specific results to be exploited by FAGOR are:
1- A software feature (option) for the CNC FAGOR8070/8065 that includes:
• Template for visual studio development or makefile for mingw compiler
• Examples for Real Time algorithms to be included in the CNC’s call path
• Filters for debugging information extraction and library for user’s data access in C.
• Tools adaptation in the CNC to access user’s data.
FAGOR will sell this as an option to potential customers (engineering companies and some machine tool manufacturers). Some assistance could be included in the form of hours of R&D people.
2- FAGOR CNC Data Logger - Recorder
Software option addressed to Machine Tool Builders and End Users. On-going requirements phase for the final product, to be sold as a software option.
PREDICT
PREDICT expect to exploit project results with Power-OM partners as part of an integrated solution or as part of PREDICT’s eMaintenance platform offering. Some added value services exploitable by PREDICT would be:
• KASEM for Machine Tool
• Machine Tool Knowledge Model
• Fleet-Wide Monitoring and Management Services
PREDICT’s objectives are to win new markets with new activities in the next years. Power-OM new products will be an important part of this turn-over. PREDICT has contractual relationships with Power-OM partners and they are organizing sale process.
MONITION
As Monition Ltd. provides expert services in the field of condition monitoring, Assets reliability and Energy management, the Power OM project will allow Monition to expand its service portfolio and thus gain further custom, especially in the manufacturing area.
Regarding the IntelliEnergy Diagnostic software module:
• Monition will continue to collaborate with the existing consortium members to develop an integrated power solution to enhance system capabilities.
• It is intended to partner with system integrators with current market share and dedicated sector expertise to speed route to market.
• The system will be developed into a general cross sector platform for use with general manufacturing industry. The concept and current deliverable is extremely adaptable to these applications.
• The fault tree diagnostic will be developed in an AI based decision module for use on a decision integrator across industry sectors.
• The system will be exploited as a service tools for installation and configuration and revenue stream will cover licencing to direct selling, also providing the platform for monition Core Reliability services.
TEKNIKER
TEKNIKERS as owner of the Machine Tool Health Assessment module, will continue the collaboration with some partners in the project, and will use this as this background in projects with other Machine-tool manufacturers.
Added to this, there is other possibilities for the exploitation of this background through other distribution channels, such as:
• Companies already present in this business segment (sensors & monitoring).
• CNC manufacturers.
GORATU
Because of the global market competition, GORATU has moved to produce customized large size milling machines and lathes.
The objective of this product is to improve the availability of GORATU milling machines by means of improving maintenance strategies.
The strategy for GORATU is:
To include the embedded software in the NC control that monitors the working conditions of the new machines.
Promote new maintenance services. The concept to push is “proactive maintenance” based on:
• Main maintenance operation remainders based on the use of the machine
• Early warning of main components performances
• Customized reports availability
(5) SCIENTIFIC DISSEMINATION
Papers published:
Green Condition based Maintenance - an integrated system approach for health assessment and energy optimization of manufacturing machines. Conference on Condition Monitoring and Machinery Failure Prevention Technologies. June 2013 in Krakow, Poland.
New technologies to optimize reliability, operation and maintenance in the use of Machine-Tools. EuroMaintenance Congress, 2014, Helsinki, Finland (clustered session with FoF projects in maintenance).
Health and Performances Machine Tool Monitoring Architecture. E-maintenance conference, under the topic Integration with Prognostic Health Management. June 2014, Luleå, Sweden.
Motor current signature analysis for gearbox health monitoring: Experiment, signal analysis and classification. PHM Europe Conference, under the topic Condition Monitoring in Rotating Machinery. July 2014, in Nantes, France.
Aggregation of electric current consumption features for extraction of maintenance KPIs. Maintenance Performance Measurement and Management (MPMM) Conference, from 4th to 5th of September 2014 in Coimbra, Portugal
Context Driven Remaining Useful Life Estimation. 3th International Conference in Through-life Engineering Services, from 4th to 5th of November 2014, in Cranfield, United Kingdom.
There are other two papers planned to be published through 2015:
• Prognosis of machine tools: A context awareness approach. Journal of Intelligent Manufacturing. Authors: LTU.
• Motor current signature analysis, using wavelets for speed transient analysis to estimate health status in spindles. IEEE transactions on Industry Applications. Authors: TEKNIKER.
(6) INDUSTRIAL DISSEMINATION
The industrial dissemination which is focus to industrial audiences such as machine tool manufacturers, maintenance services providers, OEMs, etc. is coordinate by MONITION Ltd. As part of this, researches has been carried out to identify the industrial audiences and their behaviours, the future trade fairs, events and publications oriented to the machine tool industry. Also a press release, a set of flyers and a poster has designed to inform about the project to its audience.
As mentioned above, as a part of the Task 9.1 in WP 9 in the project, PowerOM flyers were designed to inform about the project to the audiences. These were designed in five different sizes/types and in four different designs to fit in different industries. They have been distributed in five different sizes/types: A3, A3 – Regular - 2 Panel, A4, A4 – Regular - 2 Panel, A4 – Roll - 3 Panel.
Different industries:
• Aerospace and Aeronautics Industry
• Automotive Industry
• General Industries
• Vehicle Industry (Aerospace and Aeronautics, Automotive, Ship, Railway)
MONITION sent the press release to several magazines (online/printed) under the title “Power-Consumption Monitoring to Raise Machine Reliability” highlighting:
• American Machinist Website: http://americanmachinist.com/qc-and-inspection/power-consumption-monitoring-raise-machine-reliability
• Industrial Supply Asia website: http://www.industrialsupply.com.cn/EN/Co/?CID=12&AID=219
Along with the press release, the PowerOM poster also sent to the magazines. The main obstacle when trying to publish the press release is that the magazines aren’t willing to publish them for free. This has effected for the minimal response in publishing the press release.
Other than publishing the press release in the magazines MONITION is working on sending it to Machine Tool Manufactures, Machine Tool End Users and to industry specific societies (internet societies) though LinkedIn. Also MONITION distributed the flyers and poster through emails to several machine tool builders and users as a part of making aware about the project to the industry related people.
GORATU, FAGOR, TEKNIKER had a special action in the BIEMH 2014 http://www.biemh.com/en/ the international machine tool fair hold in Bilbao 30May-04 June. It was produced a brochure in Spanish (attached, later translated into Italian and English languages) and 600 paper copies were distributed in the boots of GORATU, FAGOR and TEKNIKER.
At the end of the project, a new poster was produced including as contents the main exploitable results
Power-OM Product Launch Seminar: ARTIS GmbH organised a successful product launch seminar on 24th of March 2015. The objective of the seminar was to share with industry vision, concepts, prototypes and potential products coming out from Power-OM. The seminar included demonstrations in ARTIS Lab. The relevant end users from the automotive sector and representatives from machine tool manufacturing OMEs attended to this seminar. More information about this can be found in project website.
XX Congress of Machine Tools and Manufacturing Technologies: TEKNIKER and FAGOR presented Power-OM project in the XX Congress of Machine Tools and Manufacturing Technologies which was held on 10-12 of June 2015 in San Sebastian. This event was organised by Spanish Association of Machine Tools, accessories, components and tools (AFM):
• TEKNIKER presented the concept of Machine 4.0. The implementation of this concept means between others, the development of new services based on the collaboration between machine tool manufacturer and machine users to optimise the uptime. Aligned with this objective, Power-OM results were presented.
• FAGOR presentation was about Tuning 4.0 and Services 4.0. Among others, the possibility to implement a Condition Based Monitoring strategy based on the fingerprint concept and FAGOR CNC data logger was presented.
(7) OTHER DISSEMINATION ACTIONS
Workshop on Impact of the Factories of the Future PPP – Brussels 11-12 March 2013:
Added to Power-OM, the other two projects were:
• iMain - A Novel Decision Support System for Intelligent Maintenance
• Supreme - SUstainable PREdictive Maintenance of manufacturing Equipment
Workshop on Impact of the Factories of the Future PPP – Brussels, 25-26 March 2014:
Power-OM was clustered in the Area 2 about “Maintenance, repair, re-use”. In this sense one goal was to merge related projects from different calls:
• Methodologies and tools for the sustainable, predictive maintenance of production equipment (FoF.NMP.2012-2)
• Innovative strategies for renovation and repair in manufacturing systems (FoF.NMP.2013-8)
• Innovative re-use of modular equipment based on integrated factory design (FoF.NMP.2013-2)
• Intelligent production machines and 'plug-and-produce' devices for system adaptivity (FoF.NMP.2012-3)
The expected impacts of the supported area of the projects are:
• Increase availability of production systems & OEE.
• Energy consumption reduction (10%)
• Reduction of around 20% of renovation and repair costs
• At the end-of-life stage, contribution towards a 80-100% reuse of production system components in new life cycles
• Cost reduction of around 30% due to re-use of existing modular equipment when setting-up production systems for new product variants
• Renovation of outdated plants and structures. Safe production sites
Workshop on Impact of the Factories of the Future PPP – Brussels, 29-30 April 2015:
Representatives of over 150 FoF projects were there. Power-OM project was represented again in the area of “Maintenance, Repair and Reuse”, under the theme of “Environmental sustainability”. Added to Power-OM, the clustered projects were the same as in previous edition: IMAIN, SUPREME, REBORN, WHITER, SELSUS, T-REX and EASE-R3.
From all the clustered projects, four of them (Power-OM, IMAIN, T-REX and EASE-R3) focus on maintenance and new services in machine-tool business.
Among these collaboration activities, the specific cluster action Co-FACTOR was included as a relevant one. Co-FACTOR is clustering six different running FoF projects: I-RAMP3, ReBorn, SelSus, T-REX, INTEFIX and Power-OM. The common ground is the development of ‘smart components in manufacturing’ that can be also linked to Cyber-Physical Systems (CPS), as main technologies to support the smarter production systems.
(8) FUTURE ACTIVITIES
Exhibition during next summer from 30th May to 4th June 2016; allocated in Bilbao, Spain. This is a “gathering event to make business”, where “Smart Technology for Smart Solutions” is the main topic. Goratu, Fagor and Tekniker will be involved.
List of Websites:
Public web page:
www.power-om.eu
Contact details:
Aitor Alzaga
aitor.alzaga@tekniker.es
The list of participants and their web pages links are available through the project website: http://power-om.eu/consortium.
